Introducing one or more metals into a melt comprising aluminum

ABSTRACT

An additive is provided which enables metal additions to be made to aluminum melts with good metal recovery and speed of dissolution. The additive includes a mixture comprising: 
     (a) an aluminum-comprising powder, for example commercially pure aluminum; 
     (b) a powder of one or more metals or alloys comprising the metal or metals to be introduced, for example manganese, chromium, tungsten, molybdenum, titanium, vanadium, iron, cobalt, copper, niobium, tantalum, zirconium, hafnium and silver; and 
     (c) a flux, for example one or more of potassium aluminum fluoride or potassium cryolite, potassium chloride, potassium fluoride, sodium chloride, sodium fluoride, and sodium carbonate. 
     In a preferred form, the additive is a compacted tablet of components (a), (b) and (c), in the weight proportions of about 5%, 75% and 20%, respectively. The additive is especially useful in the method of the invention of introducing one or more metals into a melt comprising aluminum. Aluminum alloys are provided which contain a metal or metals introduced by the method of the invention.

This is a division of application Ser. No. 452,112 filed Dec. 22, 1982now U.S. Pat. No. 4,564,393.

THE BACKGROUND OF THE INVENTION

1. The Field Of The Invention

This invention broadly relates to introducing one or more metals into amelt comprising aluminum. In one of its variants, an additive isprovided which enables metal additions to be made to aluminum melts withimproved metal recovery and increased speed of dissolution. Theinvention is also concerned with a method which employs the noveladditive of the invention in introducing one or more metals into a meltcomprising aluminum. The invention is further concerned with an aluminumalloy prepared by the method of the invention.

2. The Prior Art

When producing aluminum alloys, it is frequently necessary to introduceinto a melt of aluminum, or an alloy of aluminum, a metal or alloy whichwill not itself readily dissolve in the melt. Many types of masteralloys and additive mixtures have already been proposed for thispurpose, but there remains a need for an additive which, while beingeconomical to manufacture, is also capable of making such additions,both with good metal recoveries and within a short dissolution time.Some examples of prior art additives are found in U.S. Pat. No.3,592,637.

THE SUMMARY OF THE INVENTION

The present invention provides an additive which enables metal additionsto be made to aluminum melts with excellent metal recovery and increasedspeed of dissolution. The additive includes a mixture comprising analuminum-comprising powder such as for example, commercially purealuminum, a powder of one or more metals or alloys comprising the metalor metals to be introduced as described more fully hereinafter, and aflux comprised of one or more components which likewise will bedescribed more fully hereinafter.

The present invention also provides a method of introducing one or moremetals into a melt comprising aluminum which employs the above-describedadditive to thereby achieve improved metal recovery and increased speedof dissolution. The invention additionally provides an aluminum alloyprepared by the method of the invention.

THE BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The improved results that are obtained in practicing the presentinvention are further illustrated by the accompanying drawings, wherein:

FIG. 1 is a graph prepared from the data obtained in Example 1;

FIG. 2 is a graph prepared from the data obtained in Example 2;

FIG. 3 is a graph prepared from the data obtained in Example 3; and

FIG. 4 is a graph prepared from the data obtained in Example 4.

FIGS. 1-4 are discussed in greater detail hereinafter in Examples 1-4,respectively.

THE DETAILED DESCRIPTION OF THE INVENTION INCLUDING THE PRESENTLYPREFERRED VARIANTS AND EMBODIMENTS THEREOF

According to the present invention, there is provided an additive forintroducing one or more metals into a melt comprising aluminum, theadditive comprising a mixture comprising:

(a) an aluminum-comprising powder, hereinafter sometimes referred to asthe aluminum component;

(b) a powder of one or more metals or alloys comprising the metal ormetals to be introduced, hereinafter sometimes referred to as the addedmetal component; and

(c) a flux, which may be comprised of one or more components describedmore fully hereinafter.

We have found, surprisingly, that the additive in accordance with theinvention, which includes both an aluminum component and a fluxcomponent, in addition to the added metal component, can when introducedinto a melt comprising aluminum, provide a substantially bettercombination of metal recovery and speed of dissolution than would havebeen expected on the basis of the properties and amounts of the aluminumand flux components, considering these components separately.

Any aluminum alloy which does not contain objectionable amounts ofmaterials which would have a deleterious effect on the final aluminumalloy which the additive is to be used in producing may be used as thealuminum component, but it is desirable to use as pure a form ofaluminum as possible, consistent with cost considerations, and we preferto use a commercially pure aluminum as component (a). We have discoveredit is best that the weight proportion of the aluminum component (a), A,should satisfy: 2%≦A≦10%. In addition, the relationship of the aluminumcomponent, A, to the metal or alloy component (b), B, should satisfy theproportion: 9.5≦(% B/% A)≦30. It is preferred that the relationship ofthe aluminum component, A, to the metal or alloy component, B, alsosatisfy the proportion:

    12≦(% B/% A)≦18.

Greater amounts of the aluminum component can be included, but we havediscovered that increasing the amount of the aluminum component abovethis range does not lead to any advantage adequate to compensate for theconsequent increased. "diluteness" of the additive as regards the addedmetal component and/or the loss of performance due to reduction in theflux content. It was a matter of surprise to us the extent of thebeneficial effect obtainable with such small amounts of the aluminumcomponent, when in combination with the flux component, in accordancewith the invention. We prefer that A should satisfy: 4%≦A≦6%. The bestresults are often obtained when A is about 5%. Additives in accordancewith the invention are primarily intended for introducing into aluminummelts metals which have a melting point greater than that of aluminum,for example manganese, chromium, tungsten, molybdenum, titanium,vanadium, iron, cobalt, copper, niobium, tantalum, zirconium, hafniumand silver, and especially manganese, chrominum, titanium, iron andcopper. Normally, the added metal component will, for convenience, beone or more such metals in commercially pure form, but if desired, itmay be one or more alloys of such metals, provided that use of thealloy(s) will not lead to the introduction of intolerable amounts ofdeleterious components into the melt.

Where it is desired to introduce a plurality of metals into an aluminummelt, one may introduce one or more of those metals by means of anadditive in accordance with the invention, and use other means tointroduce one or more other metals. Also, where a plurality of metalsare to be introduced by means of an additive in accordance with theinvention, those metals may be present in the additive as:

(1) a mixture of powders of the metals;

(2) a powder of an alloy of the metals; or

(3) a mixture of the powders of at least one alloy and at least onemetal.

For any of the metals introduced or the metal where only only one isintroduced, part of that metal may be introduced into the bath by meansother than the additive of the invention, the rest of the metal beingintroduced by a "trimming" addition, using an additive in accordancewith the invention.

We prefer that the weight proportion of component (b), (B), shouldsatisfy: 60%≦B≦90%. Satisfying this condition enables the additive to bereasonably concentrated in the added metal component, while at the sametime obtaining fast dissolution and high added metal component recovery.We most prefer that B should satisfy: 70%≦B≦80%, and even morespecifically, B advantageously may be about 75% in many instances.

We have found that, for best results, the weight proportion of the fluxcomponent, C, should satisfy 10%≦C≦30% or 10%≦C≦35%. Preferably, C is:15%≦C≦25%. Presently preferred fluxes include one, or a mixture of twoor more, of the following chemicals: potassium aluminum fluoride orpotassium cryolite, potassium chloride, potassium fluoride, sodiumchloride, sodium fluoride and sodium carbonate. At C values less thanabout 10%, the benefits to be obtained by the inclusion of the flux aresubstantially below their maximum, and with C greater than about 35%,the consequent dilution of the other components in the additive is notadequately compensated for.

Desirably, but not essentially, the flux component should benon-hygroscopic. We have found that when such fluxes are employed, it isgenerally easier to introduce the additives into aluminum melts, and tomaintain them submerged therein. We have also found that similarly goodresults can be obtained, even where the flux is not non-hygroscopic,provided that one can arrange that the additive is not exposed tomoisture for any substantial period of time, for example by enclosing itin a moisture barrier, such as a polythene sheet material, for example,during storage prior to use.

Especially good combinations of (1) quick dissolution and (2) additivemetal recovery can be obtained when the flux component comprisespotassium aluminum fluoride, and especially when this makes up at least50% by weight of the flux component. The potassium aluminum fluoride isthe potassium analogue of cryolite, and is herein called potassiumcryolite. Where the flux is to be substantially non-hygroscopic, theflux component preferably substantially consists of a non-hygroscopicpotassium aluminum fluoride. An especially preferred additive inaccordance with the invention is one in which the aluminum component iscommercially pure aluminum, at least 50% by weight of the flux componentis potassium cryolite, and A is about 5%, B is about 75% and C is about20%. Where this additive will not be adequately protected from moistureprior to its use, we prefer that the flux should substantially consistof potassium cryolite. Particularly preferred forms of the additivesdescribed in this paragraph are those in which the added metal componentis commercially pure chromium, commercially pure manganese, commerciallypure iron, commercially pure titanium, or 90% titanium alloy.

In general, we prefer that the particles of the aluminum component andadded metal component from which the additive is formed are of particlesize minus 10 mesh or minus 20 mesh (British Standard Screen Scale,i.e., B.S.S.S.), and for some purposes we prefer the particle size to beminus 40 or minus 100 mesh (B.S.S.S.). We have found that the additivesare much easier to introduce into, and maintain within, aluminum meltswhen they are in the form of a body which has been formed by compressionof its constituents. Such bodies may be formed by compressing powderedmixtures of components (a), (b) and (c) using, for example, a rollpress, or a horizontal hydraulic pelleting machine. The mixed componentscan also be added to molten aluminum in a loose powder form by enclosurewithin protective consumable containers or by injection of the powdersinto the molten aluminum utilizing a carrier gas to transport theadditive beneath the surface of the molten aluminum.

The present invention also comprehends a method of introducing one ormore metals into a melt comprising aluminum, the method comprisingintroducing an additive in accordance with the invention into the melt,and permitting or causing the addititve to be substantially uniformlydisbursed through the melt. In many cases, the melt into which theadditive is introduced will be a commercially pure aluminum, but it maybe an alloy of aluminum, for example where an alloying addition hasalready been made to an aluminum melt. We have found that the recoveryof the component B in the melt and the rate of dissolution within themelt is improved if the density of the compacted body is greater than orequal to 4.0 grams per cubic centimeter.

The invention further comprehends an aluminum alloy, whenever containinga metal or metals introduced by a method in accordance with theinvention.

In order that the invention may be more fully understood, someembodiments in accordance therewith will now be described in thefollowing Examples. In the foregoing discussion, the Examples, and theclaims the percentages are by weight.

EXAMPLE I

A mixture of the following particulate components was prepared:

75.8% manganese powder (minus 40 mesh B.S.S.S.)

19.2% potassium cryolite

5.0% aluminum powder(minus 80 mesh B.S.S.S.)

This mixture was formed into cylindrical tablets approximately 90 mm indiameter×25 mm thick on a horizonal hydraulic pelleting machine. Thetablets had an average manganese content of about 500 g and an averagetotal weight of about 660 g.

An aluminum melt was carried out in a 5 ton capacity Monometer furnace,the charge consisting of aluminum sows and aluminum scrap . Aftermelting and dross removal, the bath temperature was adjusted to 740°C./750° C. and a sample taken for analysis; the manganese content was0.16%, and the melt weight was 2578 kg.

Tablets of the manganese additive were added through the side door ofthe furnace into the clean bath of aluminum, the total amount ofmanganese contained in the tablets being 1% of the melt weight.Surprisingly, there was very little evidence of fuming.

The bath was intermittently rabelled and the bath temperature adjustedas necessary. Samples for analysis for the weight percentage ofmanganese in the bath were taken progressively. The results are shown inFIG. 1 of the accompanying drawings, from which it can be seen thatvirtually 100% manganese recovery was achieved, about 16 minutes afteraddition.

In order to test the homogeneity of the addition, three samples weretaken at spaced-apart locations in the bath 211/2 minutes after theadditive addition. The three manganese contents as thus-measured wereidentical, within the range of analytical error.

EXAMPLE 2

A mixture of the following particulate components was prepared:

75.8% chromium powder (minus 60 mesh B.S.S.S.)

19.2% potassium cryolite

5.0% aluminum powder (minus 80 mesh B.S.S.S.)

This mixture was formed into cylindrical tablets of the same dimensionsas those prepared in Example I, using the same machine. The tablets hadan average chrominum content of about 500 g and an average total weightof about 660 g.

The procedure of Example I was repeated to prepare a clean aluminum bathat 740° C./750° C. in the Monometer furnace, and again a sample wastaken for base analysis. In this case the melt weight was 3360 kg andthe base analysis was:

0.01% chromium

0.25% silicon

0.17% manganese

0.65% iron.

Tablets of the chrominum additive were added through the side door intothe clean bath of aluminum, the total amount of chromium contained inthe tablets being 0.21% of the melt weight. Once again, there was verylittle evidence of fuming. As in Example I, the bath was intermittentlyrabbled and the bath temperature adjusted as necessary, and samples foranalysis for the weight percentage of chromium in the bath were takenprogressively. The results are shown in FIG. 2 of the drawings, fromwhich it will be seen that virtually 100% chromium recovery wasachieved, about 25 minutes after addition. Three samples taken 19minutes after the additive addition at spaced apart locations in thebath gave identical chromium content measurements.

EXAMPLE 3

A mixture of the following particulate components, all minus 100 mesh,was prepared:

75% chromium containing 3% aluminum

5% aluminum powder

12.5% potassium chloride

4.0% sodium chloride

3.5% potassium cryolite

This mixture was formed into pillow-shaped tablets approximately 25.4mm×14.3 mm on a roll press.

In order to compare the performance of this product in accordance withthe invention with two prior art products, three tests were run in thelaboratory, under identical conditions, which did not, however, entirelymatch those existing in commercial practice. In particular, the bathwas, of course, much smaller than in commercial practice and this led torather shorter dissolution times than would normally be obtained incommercial practice. The first prior art product was a commerciallyavailable product, which was in briquette form, and which was made up of75% chromium powder and 25% aluminum powder. The second prior artproduct was in the form of pillow-shaped tablets made in the same manneras the pillow-shaped tablets described at the beginning of this Example,with the modification that the alumimum powder was replaced byadditional flux, the weight proportions of the three flux constituentsbeing unchanged.

In each test, the additive was introduced into a molten aluminum bath insuch an amount that the chromium in the additive was 0.2% of the weightof the bath, and bath samples were removed at regular time intervals foranalysis for the weight percentage of chromium in the bath. The resultsare shown in FIG. 3, wherein Curve *1 relates to the additive inaccordance with the invention, Curve *2 relates to the first prior artproduct (75% chromium/25% aluminum), and Curve *3 relates to the secondprior art product (75% chromium/25% flux). As will be seen,substantially the same recovery was obtained in the case of the firstprior art product (Curve *2) as in the case of the product in accordancewith the invention (Curve *1), but this recovery was achieved in a muchshorter time (about 6 minutes) with the product in accordance with theinvention than with the prior art additive (about 18 minutes). Theoverall performance of the second prior art product (Curve *3) wasmarkedly inferior.

EXAMPLE 4

Three further batches of pillow-shaped tablets in accordance with theinvention were prepared in the same manner as in Example 3, with theexception that the amount of flux was varied, with correspondingvariations in the amount of chromium powder. These additional batcheshad the following respective percent compositions:

    ______________________________________                                        chromium (containing 3% aluminum)                                                                   90       60    50                                       aluminum powder       5         5     5                                       flux                  5        35    45                                       ______________________________________                                    

In each case, the flux consisted of potassium chloride, sodium chlorideand potassium cryolite, in the same weight proportions as in the tabletsof Example 3 in accordance with the invention.

These three batches were tested in the same manner as in Example 3,under the same conditions, and in each case the percentage of the totalchromium contained in the additive which had gone into solution in thebath after 6 minutes was noted. The results are shown in FIG. 4, whichalso shows the corresponding figures relating to the additive inaccordance with the invention and the prior art additives tested inExample 3. The figures relating to the additives in accordance with theinvention are plotted as Curve 1, and points 2 and 3 respectively showthe results obtained with the first and second prior art additives.

EXAMPLE 5

A mixture of the following components was prepared:

75% electrolytic manganese metal

5% aluminum powder

12.5% potassium chloride

4.0% sodium chloride

3.5% potassium cryolite

This mixture was formed into briquettes approximately 7/8 inch by 1/2inch. An addition equivalent to 1.23% manganese was made to a 3.6 poundbath of molten aluminum. Samples were taken from the molten bath priorto the addition and at intervals throughout the test after agitation ofthe bath.

    ______________________________________                                        TIME FROM ADDITION                                                                             ACTUAL ANALYSIS (% Mn                                        IN MINUTES       DISSOLVED IN BATH)                                           ______________________________________                                         0                0.003                                                        1               1.07                                                          5               1.22                                                         10               1.17                                                         15               1.25                                                         20               1.22                                                         25               1.20                                                         ______________________________________                                    

More than 97% of the manganese addition was dissolved within fiveminutes of the initial addition. The overall recovery of over 97% wasexcellent.

EXAMPLE 6

A mixture of the following components was prepared:

75% iron powder

5% aluminum powder

12.5% potassium chloride

4.0% sodium chloride

3.5% potassium cryolite

This mixture was formed into briquettes approximately 7/8 inch by 1/2inch. An addition equivalent to 0.53% iron was made to a 3.4 pound bathof molten aluminum having an iron content of 0.17%. Samples were takenfrom the bath prior to the addition and at intervals throughout the testafter agitation.

    ______________________________________                                        TIME FROM ADDITION                                                                            ACTUAL ANALYSIS                                               IN MINUTES      (PERCENT IRON DISSOLVED)                                      ______________________________________                                         0              0.17                                                           1              0.55                                                           5              0.65                                                          10              0.67                                                          15              0.69                                                          20              0.69                                                          25              0.67                                                          ______________________________________                                    

Comparing the aim of the addition (0.70%) against the analysis of thebath, it is evident that both fast dissolution rate and recovery inexcess of 95% were achieved.

The potassium aluminum fluoride referred to in the foregoing descriptionas potassium cryolite may be any non-hygroscopic salt materialcontaining potassium, aluminum and fluorine in proportions consistentwith the salt being a mixture of AlF₃ and KF, and capable of melting ata temperature below that of the bath into which the additive is to beintroduced. However, in practice the salt material generally will not bein the form of a simple mixture of AlF₃ and KF, at least when in themolten condition when in use; see the KF-AlF₃ phase diagram of FIG. 1 ofthe paper Furnace Brazing OF Aluminium With A Non-Corrosive Flux by W.E. Cooke, T. E. Wright and J. A. Hirschfield, published in 1978 by theSociety Of Automotive Engineers, Inc., Pennsylvania, U.S.A. as TechnicalPaper Series 780,300, ISSN 0148-7191. The phase diagram was taken fromB. Jansen, Phase And Structure Determination Of New Complex AlkaliAluminium Fluoride", Institute Of Inorganic Chemistry, NorwegianTechnical University, Trontheim, 1969.

Preferably, the potassium aluminum fluoride should have as low a meltingtemperature as possible, and most preferably below about 600° C. Forthis reason, we prefer that (regarding the potassium cryolite as amixture of KF and AlF₃) the molar percentage of AlF₃ should lie betweenabout 45% and 50%. The potassium cryolite employed in the foregoingExamples was obtained from the London and Scandinavian MetallurgicalCompany Limited, Rotherham, England under the description potassiumaluminum fluoride, and had a molar AlF₃ percentage falling within thisrange.

We claim:
 1. A method of introducing at least one additive metallicmaterial into a melt comprising aluminum which (comprises) comprisesintroducing into the said melt an additive composition (comprising)consisting of as essential ingredients an intimate admixture containingthe following components:(a) a metallic aluminum-comprising powder; (b)a powder of at least one additive metallic material to be introducedinto the said melt selected from the group consisting of metallicmanganese, chromium, tungsten, molybdenum, titanium, vanadium, iron,cobalt, copper, niobium, tantalum, zirconium, hafnium, silver and alloysthereof; and (c) a flux component (comprising at least one fluxingmaterial) selected from the group consisting of (alkali metal-containinghalide fluxes, alkali metal-containing carbonate fluxes,) potassiumaluminum fluoride (potassium cryolite), potassium chloride, potassiumfluoride, sodium chloride, sodium fluoride, sodium carbonate, andadmixtures thereof.
 2. The method of claim 1 wherein the weightproportion of component (a), A, satisfies both: 2%≦A≦10% and 9.5≦(% B/%A)≦30.
 3. The method of claim 1 whereinthe weight proportion ofcomponent (a),A,satisfies: 4%≦A≦6%.
 4. The method of claim 1 whereintheweight proportion of component (b),B,satisfies: 60%≦B≦90%.
 5. Themethod of claim 1 wherein theweight proportion of component (b),B,satisfies: 70%≦B≦80%.
 6. The method of claim 1 wherein theweightproportion of component (c),C,satisfies: 10%≦C≦35%.
 7. The method ofclaim 1 wherein the weight proportion of component (c),C,satisfies:15%≦C≦25%.
 8. The method of claim 1 wherein component (a) is acommercially pure aluminum powder.
 9. The method of claim 1 whereincomponent (b) is a powder of at least one additive metallic material tobe introduced into the said melt selected from the group consisting ofcommercially pure metallic manganese, chromium, titanium, iron, copper,and alloys thereof.
 10. The method of claim 1 wherein the said additivemetallic material is manganese.
 11. The method of claim 1 wherein thesaid additive metallic material is chromium.
 12. The method of claim 1wherein the said additive metallic material is iron.
 13. The method ofclaim 1 wherein the components (a) and (b) have a particle size of minus10 mesh (British Standard Screen Scale).
 14. The method of claim 1wherein the components (a) and (b) have a particle size of minus 40 mesh(British Standard Screen Scale).
 15. The method of claim 1 wherein thecomponents (a) and (b) have a particle size of minus 100 mesh (BritishStandard Screen Scale).
 16. The method of claim 1 wherein the component(c) consists of potassium aluminum fluoride (potassium cryolite). 17.The method of claim 1 wherein the Component (c) consists of at least onefluxing material selected from the group consisting of non-hygroscopicfluxes, hygroscopic fluxes, and admixtures thereof.
 18. The method ofclaim 1 wherein the weight proportion of component (a), A, satisfiesboth 2%≦A≦10% and 9.5≦(% B/% A)≦30, the weight proportion of component(b), B, satisfies 60%≦B≦90%, the weight proportion of component (c), C,satisfies 10%≦C≦35%, and the components (a) and (b) have a particle sizeof minus 10 mesh (British Standard Screen Scale).
 19. The method ofclaim 18 wherein the weight proportion of component (a), A, satisfies4%≦A≦6%,the weight proportion of component (b),B, satisfies 70%≦B≦80%.the weight proportion of component (c), C, satisfies 15%≦C≦25% and thecomponents (a) and (b) have a particle size of minus 40 mesh (BritishStandard Screen Scale).
 20. The method of claim 19 wherein thecomponents (a) and (b) have a particle size of minus 100 mesh (BritishStandard Screen Scale), the said fluxing material comprises potassiumaluminum fluoride (potassium cryolite), the said admixture of components(a), (b) and (c) has been formed into briquettes by compression, and thedensity of said briquettes is at least 4.0 g/cc.
 21. The method of claim20 wherein the said admixture consists of about 5% by weight ofcomponent (a), about 75% by weight of component (b) and about 20% byweight of component (c), and the said fluxing material comprisespotassium aluminum fluoride (potassium cryolite) having a melting pointbelow 600° C.
 22. A method of introducing at least one additive metallicmaterial into a melt comprising aluminum which comprises introducinginto the said melt an additive composition consisting of as essentialingredients an intimate admixture containing the followingcomponents:(a) a metallic aluminum-comprising powder; (b) a powder of atleast one additive metallic material to be introduced into the said meltselected from the group consisting of metallic manganese, chromium,tungsten, molybdenum, titanium, vanadium, iron, cobalt, copper niobium,tantalum, zirconium, hafnium, silver and alloys thereof; and (c) a fluxcomponent consisting of as an essential ingredient at least one fluxingmaterial selected from the group consisting of alkali metal-containinghalide fluxes, alkali metal-containing carbonate fluxes, and admixturesthereof: and wherein the weight proportion of component (a), A, in saidadditive composition satisfies both: 2%≦A≦10% and 9.5≦(%B/%A)≦ 30 , theweight proportion of component (b) ,B, satisfies: 60%≦B≦90%; and theweight proportion of component (c),C, satisfies: 10%≦C≦35%.
 23. Themethod of claim 22 wherein theweight proportion of component (a), A,satisfies 4%≦A≦6%, the weight proportion of component (b),B, satisfies70%≦B≦80%,and the weight proportion of component (c), C, satisfies15%≦C≦25%.
 24. The method of claim 22 wherein the weight proportion ofcomponent (a),A, satisfies: 4%≦A≦6%.
 25. The method of claim 22 whereinthe weight proportion of component (b),B, satisfies: 70%≦B≦80%.
 26. Themethod of claim 22 wherein the weight proportion of component (c),C,satisfies: 15%≦C≦25%.
 27. The method of claim 22 wherein component (a)is a commercially pure aluminum powder.
 28. The method of claim 22wherein component (b) is a powder of at least one additive metallicmaterial to be introduced into the said melt selected from the groupconsisting of commercially pure metallic manganese, chromium, titanium,iron, copper, and alloys thereof.
 29. The method of claim 22 wherein thesaid additive metallic material is manganese.
 30. The method of claim 22wherein the said additive metallic material is chromium.
 31. The methodof claim 22 wherein the said additive metallic material is iron.
 32. Themethod of claim 22 wherein the components (a) and (b) have a particlesize of minus 10 mesh (British Standard Screen Scale).
 33. The method ofclaim 22 wherein the components (a) and (b) have a particle size ofminus 40 mesh (British Standard Screen Scale).
 34. The method of claim22 wherein the components (a) and (b) have a particle size of minus 100mesh (British Standard Screen Scale).
 35. The method of claim 22 whereinthe component (c) consists of at least one fluxing material selectedfrom the group consisting of potassium aluminum fluoride (potassiumcryolite), potassium chloride, potassium fluoride, sodium chloride,sodium fluoride, sodium carbonate, and admixtures thereof.
 36. Themethod of claim 22 wherein the component (c) consists of potassiumaluminum fluoride (potassium cryolite).
 37. The method of claim 22wherein the Component (c) consists of at least one fluxing materialselected from the group consisting of non-hygroscopic fluxes,hygroscopic fluxes, and admixtures thereof.
 38. The method of claim 23wherein the components (a) and (b) have a particle size of minus 10 mesh(British Standard Screen Scale).
 39. The method of claim 23 wherein thecomponents (a) and (b) have a particle size of minus 40 mesh (BritishStandard Screen Scale).
 40. The method of claim 39 wherein thecomponents (a) and (b) have a particle size of minus 100 mesh (BritishStandard Screen Scale), the said fluxing material consists of potassiumaluminum fluoride (potassium cryolite), the said admixture of components(a), (b) and (c) has been formed into briquettes by compression, and thedensity of said briquettes is at least 4.0 g/cc.
 41. The method of claim40 wherein the said admixture consists of about 5% by weight ofcomponent (a), about 75% by weight of component (b) and about 20% byweight of component (c), and the said fluxing material comprisespotassium aluminum fluoride (potassium cryolite) having a melting pointbelow 600° C.